Apparatus and method of forming a flexible pouch with improved side seam

ABSTRACT

An improved flexible pouch, apparatus and methodology for a pouch having an upper edge, a lower edge, and side edges extending therebetween. The side seal is 4-6±1 mm wide. The apparatus and method includes the steps of unrolling the material along a horizontal orientation, and turning the sheet of material to have a vertical orientation. The method also checks the alignment of the sheet of material, and adjusts the alignment relative to a vertical axis, to align the outer edges of the sheet of material. The method cuts the roll width of material into sections, and positions the aligned sections together to form the body of the pouch. The method forms side seams by sealing along the side edges of each pouch. The method also separates the individual pouches from the roll width of material, and removes the pouches from the machine.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority of U.S. Provisional Patent ApplicationSer. No. 60/772,949 filed Feb. 14, 2006, which is incorporated herein byreference.

FIELD OF THE INVENTION

The present invention relates generally to a flexible pouch forpackaging a product and, more specifically, to a flexible pouch with animproved side seam for packaging a product and an apparatus and methodof manufacturing the same.

BACKGROUND OF THE INVENTION

Various types of disposable, portable containers are known in the artfor storing a fluid or dry product, such as a liquid, granular material,powder or the like. One example of such a container is a flexible pouch.Consumers prefer the convenience of flexible pouches, due to theirshape, size, shelf life and storage adaptability. Manufacturersrecognize the packaging benefits of a flexible pouch, since the pouchcan be formed and filled on the same manufacturing line. An example of amethod and apparatus for filling a flexible pouch with a product isdisclosed in commonly assigned U.S. Pat. No. 6,199,601, which isincorporated herein by reference.

The flexible pouch is made from a flexible material, such as anextrusion or a laminate composed of sheets of plastic or aluminum or thelike. An outer layer of the material may have preprinted information,such as a logo or the like, to provide the consumer with informationregarding the contents of the pouch. The material is available in sheetform, on a roll, and a plurality of pouches may be fabricated from onewidth of the roll.

The pouch may be formed using conventionally known manufacturingtechniques, such as a horizontal form-fill-seal machine with single ormultiple lanes, a flat bed pre-made pouch machine, a verticalform-fill-seal machine, or the like. The machine includes a number ofstations, with a particular operation or operations taking place at eachstation. The pouch is generally formed by folding a sheet or sheets ofmaterial over each other to achieve a predetermined shape. The pouch mayalso include an insert or gusset positioned between two parallel edgesto form a pouch capable of standing unsupported. Edges, such as a sideedge may be joined together using a sealing technique such as bonding orwelding. Alternatively, the roll is folded to form a pouch with threeopen sides. An upper edge of the front panel and back panel is generallynot sealed until after the pouch is filled. The empty pouch may beplaced in a corner, or gripper assembly or a holder such as a cup orpuck or combination of both prior to the filling process. The pouch isready to be filled, sealed and finished as required.

It is advantageous to concurrently form a plurality of pouches from onewidth of the roll of material, or multiple lanes across the machine bed.For example, a high speed multiple lane machine, can form approximately100-200 pouches per lane in a minute. At such a high machine speed, itis important to control the tolerance of the side seam. Each pouchformed from the roll width typically has a side seam dimension of 5-10mm and tolerance of ±2 mm, for a total seam dimension in the range of3-12 mm. Present manufacturing techniques require this large of seamsize and tolerance due to slippage of the unrolling material during thehigh speed manufacturing process. However, the failure rate of thenarrow seam increases due to this large variation. The integrity of theside seal is an important functional feature of the pouch, and a poorseal can lead to a failure of the seam. Thus, there is a need in the artfor an apparatus and method of making a flexible pouch with an improvedside seam seal width and tolerance.

SUMMARY OF THE INVENTION

Accordingly, the present invention is an improved flexible pouch for aproduct and an improved apparatus and method for manufacturing thepouch. The flexible pouch includes a front panel and a back panel eachhaving an upper edge, a lower edge opposite the upper edge, and sideedges extending therebetween the upper and lower edges. The side seal is4-6 mm±1 mm wide.

The apparatus and method of forming a pouch with a reduced side seamseal includes the steps of unrolling a sheet of material having apredetermined width along a horizontal orientation, and turning thesheet of material to have a vertical orientation. The method alsoincludes the steps of checking the alignment of the sheet of material,and adjusting the alignment with respect to a vertical axis, so that theedges of the sheet of material are in alignment. The method furtherincludes the steps of cutting the roll width of material in halt andjoining the two material sections together to form the front and backpanels of the pouches in the width of material. The method still furtherincludes the step of delineating individual pouches in the roll width ofmaterial by sealing together the side edges and lower edge of eachpouch. The method also includes the steps of separating the individualpouches from the roll width of material, sorting the pouches andremoving the pouches from the pouch-forming machine.

One advantage of the present invention is that a flexible pouch with animproved side seam and method of making such a flexible pouch using ahigh speed apparatus that moves the film in multiple index steps in alinear manner is provided. Another advantage of the present invention isthat the method of making the flexible pouch results in more preciseside seams, with a reduced seam width and tolerance. Still anotheradvantage of the present invention is that the flexible pouch hasimproved pouch strength and stability. A further advantage of thepresent invention is that the method of making a flexible pouch withimproved side seam is cost effective since less laminate material isrequired. Still a further advantage of the present invention is that themethod and apparatus for making the flexible pouch improves thecost-effectiveness of manufacturing the pouch.

Other features and advantages of the present invention will be readilyappreciated, as the same becomes better understood after reading thesubsequent description taken in conjunction with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an elevational view of a flexible pouch with improved sideseam, according to the present invention.

FIG. 2 is a flowchart of a method of forming and filling the flexiblepouch of FIG. 1, according to the present invention.

FIG. 3 a is an elevational view of the film as it is unrolled, accordingto the present invention.

FIG. 3 b is an elevational view of the film after it is cut, accordingto the present invention.

FIG. 4 is an elevational view of an apparatus for forming a flexiblepouch using the method of FIG. 2.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, a flexible pouch 10 is illustrated. The pouch 10 isfilled with a product (not shown) and sealed. The filled pouch mayassume various shapes, such as cylindrical, cube, conical or the like.The type of product and usage of the pouch influences the shape. Thetype of product is unlimited, and could have a solid or a liquid form.

The flexible pouch 10 is preferably formed from a roll of flexible,preprinted laminate material. The choice of laminate material isnonlimiting, and is influenced by factors such as the product containedin the pouch 10, the shape of the pouch or the anticipated use of thepouch. Preferably, the laminate is either a three, four or five gaugematerial, and the outer layer is preprinted. It should be appreciatedthat a portion of the material may be a clear laminate, in order to viewthe contents of the pouch. For example, the laminate material mayinclude at least one layer of virgin polyethylene terphalate (PET) andat least one layer of aluminum foil (AL) and another layer such as EVOH,PET, polyethylene, or polypropylene or nylon or the like. The laminatemay also include a metalized foil paper layer laminated to a castpolypropylene layer and another layer of PET, polyethylene or EVOH. Itshould be appreciated that there may be a fourth layer of nylon. Anothermaterial example includes a cast polypropylene (CPP) layer, apolyethylene (PET) layer, a foil (AL) layer, a nylon (ONO) layer andanother CPP layer. Another example of a material structure is the use ofnylon, foil, nylon, and cast polypropylene (ONO/AL/ONO/CPP) orCPP/NY/AL/CPP. A further example of a laminate material structure isCPP/AL/ONO/PE. This structure works well when the product has a shortshelf life, and the nylon eliminates stretching or cracking of the ALlayer. Advantageously, a pouch 10 made using the cast polypropylenelaminate material retains its filled shape even as the product isremoved from the pouch 10. It should be appreciated that if a filledcarbonated pouch is stored at ambient temperature, the laminate willstart to creep after a period of time, such as ten days. The laminatematerial may include an extrusion layer to contain “creepage” or“stretch” of the film after filling due to carbonation expansion, if theproduct is carbonated. In addition, the selected material may beorganoleptic compliant in order to avoid the transfer of odorcontaminants to the product, or product contamination during the shelflife period of the product.

The pouch 10 itself is defined by a panel, which may be formed using oneor more sheets of material. In this example, the pouch 10 includes afront wall 12 and a back wall 14, and the edges are joined along a seam.With one sheet of material, it is folded so that the outer edges arejoined together to form one seam. Alternatively, the pouch may be formedfrom two facing panels of material that are joined together alongcorresponding side edges.

Further, the pouch is defined by an upper edge 16, an opposed lower edge18, and at least one side edge 20 extending therebetween the upper andlower edges 16, 18. The edges of the pouch 10 are sealed using heat orultrasonically or by a combination of heat and ultrasonically. In thisexample, the pouch includes three fin-style seams, such as an upperseam, a bottom seam and a side seam 22. The side seam 22 has a width of4-6 mm with a tolerance of ±1 mm. One of the seams may include a fitmentsealed between the walls of the pouch, such as a spout.

The pouch 10 may include a sidewall. The sidewall advantageously allowsthe pouch 10 to acquire another shape, such as cylindrical, or to standupright. The sidewall may be integrally formed in the panel as a gusset24 or a separate piece of material as an insert (not shown). Thesidewall may be located between the side edges of the panels, betweenthe lower edges, between the upper edges, or a combination thereof. Thegusset 24 or insert may be generally wider at the lower edge and taperupwardly towards the upper edge, or be of a uniform dimension. Thesidewall may be formed between the lower edges of the pouch 10 toprovide a base for the pouch 10 to stand upright. A sidewall formedbetween the side or upper edges may serve as an area for receiving anopening means 26, to be described.

The pouch 10 further includes an opening means 26 for accessing thecontents of the pouch. Various types of opening means 26 are known inthe art for this purpose. An example of an opening means 26 foraccessing the contents or dispensing the contents from the pouch 10 is acap secured to a fitment. The fitment is made from a material such aspolypropylene. It should be appreciated that the fitment is usuallyapplied prior to filling the pouch. The fitment is sealed, such asultrasonically or heat sealed, between the edges of the pouch. The pouch10 may be filled through the open opposite end or through the spout. Thespout fitment may have a tamper-evident means. If the product is acarbonated product, the spout fitment may include a carbonation insertand oxygen scavenger to reduce oxygen in the head space.

Another example of an opening means 26 is a straw-pierceable portion forreceiving a straw. Still another example of an opening means is aresealable fitment, such as a zipper that is sold under the nameTopTite™. A further example of an opening means 26 is a tear-offportion. The tear-off portion usually has an integral tear notch 28 forinitiating the tearing. Still a further example of an opening means is apull tab covering an opening in the pouch.

It should be appreciated that the pouch 10 may include other componentsor features, as is known in the art. For example, the unfilled flexiblepouch 10 may advantageously include a guide packet formed in a panel orwall of the pouch 10 prior to filling and sealing, to facilitate theseparation of the front and rear panels prior to the filling of thepouch 10. An example of a pouch with a guide pocket is disclosed incommonly assigned U.S. patent application Ser. No. 10/310,221. Stillanother example of a component or feature is an integrally formed label,which may include a barcode. The barcode enables information, such asshipping data, of shelf life or the like, to be read by a scanner.

The pouch 10 may form one compartment for the product. Alternatively,the pouch 10 may include multiple discrete compartments. An example ofsuch a pouch is disclosed in commonly assigned U.S. patent applicationSer. No. 11/367,613, which is incorporated herein by reference. Further,the pouch may incorporate any of the above-described features in anycombination. The finished pouch may assume various shapes, such ascylindrical, cubical, conical or the like, as influenced by the type ofproduct and intended usage of the pouch.

Referring to FIG. 3, a method for forming the flexible pouch 10 usingthe high speed machine 70 described with respect to FIG. 3 isillustrated. The method begins in block 100 at a first station with thestep of providing a roll of material 30 and unrolling the film from theroll along a horizontally oriented plane. The initial width of the rollof material is determined by the desired finished size of the pouch 10and the number of pouches obtained from the width. Typically, three tofour pouches, representing six to eight panels, as shown at 32, can beobtained from a width of the roll of material on a three lane machine orfour lane machine, respectively. The film may pass through anultraviolet light chamber without reflection to remove pathogen andmicrobiological contaminants.

The method advances to block 110 and the planar orientation of theunrolling material 30 is changed from a horizontal orientation to avertical planar orientation. For example, the machine 70 utilizes anangled roll bar to modify the planar orientation of the unrollingmaterial. The vertical orientation is advantageous in aligning theunrolling material 30 prior to cutting. A precise alignment isadvantageous, especially at a higher machine speed, because the seamtolerance is more precise. A tighter tolerance reduces the amount ofmaterial required.

The methodology advances to block 115 and the alignment of the unrollingmaterial at a predefined location is determined. For example, an opticalreading means may be utilized, such as an optical scanner or the like.The optical reading means preferably identifies a predetermined portionlocation of the material, such as an edge of the material or aregistration mark as shown at 34. As previously described, the roll is apreprinted laminate of material layers. An outer layer of the preprintedmaterial may include a locating indicia (not shown), such as aregistration mark 34, for checking the alignment of the material. Theregistration marks may be positioned on the material to denote an outeredge of the material.

The methodology advances to block 120 and the determined alignment ofthe unrolling material is used to automatically correct the alignment ofthe unrolling material. In this example, a moveable roller is utilizedto adjust the alignment of the material along a vertically orientedaxis. Preferably, the adjustment movement is ±2 degrees from thevertically oriented axis.

The methodology advances to block 125 and the roll width of the alignedunrolling material is cut into sections at a cutting station. In thisexample, the material is split into two sections 36 at the cuttingstation. Each section 36 has an outer surface and an inner surface 36 a,36 b.

The methodology advances to block 130 and one of the two sections ofmaterial is rotated 180 degrees and positioned on top of the othersection of material, so that the inner surfaces 36 a, 36 b face eachother, as shown in FIG. 4 b. It should be appreciated that the outermostedges of each section of material are automatically in alignment, sincethe sections were in alignment prior to the step of cutting as shown at44.

The methodology advances to block 135 and a features such as a gusset orinsert is optionally applied between the aligned first and secondunrolling sections of material. A fitment, such as a spout, may beinserted at this station, or alternatively at a later station.

The methodology advances to block 140 and an edge is sealed. Forexample, a seam 22 defining each of the pouches 32 in the roll width ofmaterial 30 is formed in the aligned first and second unrolling sectionsof material, as shown in FIG. 4 b. In this example, the seam 38 is aside section 22. The lower edge of each pouch may also be sealed at thistime. For example, a seal is applied to the combined first and secondunrolling sections of material to form each of the side seams joiningeach front panel to each back panel in a heat-sealing operation. Thewidth of the side seal seam for each individual pouch is approximately4±1 mm. It should be appreciated that two side seal seams may beadjoining, and the seal width increased to 8±1 mm. Advantageously, theprecise alignment of the roll of material prior to cutting out thesections used to form the pouch panels allows for a decrease in thewidth of the side seal. One example of a sealing process is a heat weldthat includes the application of heat and compression. Another exampleof a seal is an ultrasonic seal. Still another example of a seal is acombination of a heat seal and an ultrasonic seal.

The methodology advances to block 145, and each of the pouches areseparated from each other, such as at a cutting station. For example,each section of material may be first separated into panels along itswidth, or through the side seam of the pouches as shown at 38. Thepouches are then separated into individual pouches as shown at 40. Inthis example, the width represents the side seams. The material is cutusing a known cutting apparatus, such as a laser or punch or the like.The pouches may be separated using a double stop cutting process,whereby two cuts are made at the same time, to separate the upper andlower edges of two pouches at the same time from the sheet of material.

The methodology advances to block 150 and the separated pouches arefurther finished. For example, a lower edge 18 of the pouch may betrimmed to shape, i.e. the corners may be angled. The cut may beperformed using a cutter or a die cut or the like. Alternatively, themethodology may include the step of applying a fitment. The sequencingof this step is determinable by the type of fitment.

The methodology may include the step of forming a crease or guide pocketa top portion of each panel 12, 14 in a creasing operation in order tofacilitate opening and filling the pouch. An example of a method offorming a crease in a panel to facilitate opening the pouch is disclosedin commonly assigned patent application Ser. No. 10/310,221, which isincorporated herein by reference.

The methodology advances to block 155 and the pre-made pouch 10 is thenremoved from the machine and is ready for filling. The formed pouch maybe loaded into a carrier and the carrier is transferred to a fill-sealmachine. It should be appreciated that the fill-seal machine may beintegral with the pouch forming machine, or may be a separate machine.

It should be appreciated that a particular manufacturing station mayperform one or a plurality of operations, to enhance the efficiency ofthe methodology and apparatus.

Referring to FIG. 4, a machine 70 for carrying out the method describedwith respect to FIG. 3 is illustrated. Various styles of machines 70 arecontemplated for filling the pouch 10, such as a flat bed, conveyor orthe like. An example of such a machine is manufactured by Nishibe, suchas the model number SBM500, SMB600 or SMB700. The machine includes abase 92 and a transport means 90, such as a conveyor, that transportsthe material through the various stations. The roll of material ismounted along a horizontally oriented axis, and is unrolled along at amaterial feed station 72. The machine 72 includes a plurality of rollersthat changes the orientation of the unrolling material from a horizontalorientation to a vertical orientation at a material turning station 74.

The unrolling material passes through an alignment station 76. At thealignment station, material rolls pass through an optical reader. Aspreviously described, the optical reader reads a predefined point withrespect to the material. This predefined point may be a registrationmark on the material, or the edge of the material.

The machine utilizes the registration marks 34 to automatically adjustthe orientation of the unrolling material position along a verticallyoriented axis. For example, rollers are used to adjust the position ofthe unrolling material ±2 degrees relative to a vertically orientedcenter axis.

The machine includes a cutting station 78 where the aligned material iscut into a predetermined number of sections, which in this example aretwo. One of the sections is rotated 180 degrees, and the first andsecond sections of this example are positioned such that inner sidesface one another. The sections are used to form the front panel and backpanel of the pouch, respectively.

It should be appreciated that a feature, as previously described, may beadded between the facing sheets at an appropriate station, such as theinsert station shown at 79. The facing sections are transferred alongthe conveyer to a sealing station 80. The sealing station, as previouslydescribed, forms the seams joining the facing sections of material anddelineating each pouch. In this example, the side edges of each of thepouches along the width of material are heat-sealed in this operation.Because of the precise alignment of the material sheets, the width ofthe side edge seam is 4 mm, with a tolerance of ±1 mm.

The material is moved along the conveyer 90 to a cutting station 82 andthe material is cut into individual pouches. For example, the pouch iscut along the side seam. The pouch is then cut along the upper edge andlower edge.

The conveyer 90 then transfers the individual pouches to an unloadingstation 84, wherein the individual pouches are taken off the conveyorand placed into a receptacle 96, such as a holder, or magazine or thelike. It should be appreciated that the pouches 10 are fully formed,except for that the upper edges 16 of the panels 12, 14 are unsealed.

The pouches are now ready for filling. It should be appreciated that thepouches may be filled and sealed on another machine, or at fill-sealstations associated with the above described machine.

The present invention has been described in an illustrative manner. Itis to be understood that the terminology which has been used is intendedto be in the nature of words of description rather than of limitation.

Many modifications and variations of the present invention are possiblein light of the above teachings. Therefore, within the scope of theappended claims, the present invention may be practiced other than asspecifically described.

1. A flexible pouch with an improved side seam for packaging a product,said pouch comprising: a front panel having an inner surface and anouter surface, and an upper edge, an opposed lower edge and side edgesextending therebetween the upper edge and the lower edge; a back panelhaving an inner surface and an outer surface, and an upper edge, anopposed lower edge and side edges extending therebetween the upper edgeand the lower edge wherein the front panel inner surface faces the backpanel inner surface; a side seal joining the front panel to the backpanel along a side seam, wherein the side seam has a width of 4-6 mm±1mm; and an opening means formed in the pouch for accessing the productcontained within the pouch.
 2. The pouch as set forth in claim 1 whereinthe pouch includes an insert positioned between the front panel loweredge and back panel lower edge so that the pouch can stand upright.
 3. Amethod of forming a flexible pouch having an improved side seam, saidmethod comprising the steps of; providing a roll of flexible materialhaving a material locating indicia positioned at a predeterminedlocation on the flexible material; unrolling the material from the rollalong a horizontally oriented plane; changing a planar orientation ofthe unrolling material to a vertically oriented plane; checking thealignment of the unrolling material with respect to a verticallyoriented axis using the material locating indicia, and correcting thealignment if the unrolling material is out of alignment; cutting thealigned material into at least two sections, wherein each section has aninner surface and an outer surface, and an outer edge; rotating a firstsection 180 degrees and placing the first section on top of a secondsection, so that the inner surface of the first section faces the innersurface of the second section, and the outermost edges of the firstsection and the second section are in alignment; forming a side seamdefining adjacent pouches in the aligned sections, wherein the width ofthe side seam for each pouch is 4-6 mm±1 mm; sealing a lower edge of thepouch using a sealing means; and separating the adjacent pouches in thealigned sections into individual pouches along an outermost edge of eachside seam.
 4. The method as set forth in claim 3 wherein said step ofaligning the material includes the step of adjusting the position of thematerial 2 degrees from a vertically oriented axis.
 5. The method as setforth in claim 3 further includes the step of positioning an insertbetween the front panel and back panel prior to the step of sealing. 6.The method as set forth in claim 4 wherein the step of forming the sideseam includes using a heat weld to form the side seam.
 7. The method asset forth in claim 3 further including the step of including an openingmeans in the pouch for dispensing product from the pouch.
 8. Anapparatus for forming a flexible pouch for a product that has animproved side seal comprising: a base; a transport means secured to thebase for transporting a film of laminate material, wherein the film oflaminate material is provided on a roll and includes a registration markin a predetermined location; a material feed station for unrolling theroll of laminate material along a horizontal plane; a material turningstation for modifying the orientation of the unrolling material to avertical plane; an alignment station for checking the alignment of theunrolling material, wherein the alignment station includes an opticalreading means that identifies the registration mark and uses theregistration mark to determine if the material is in alignment withrespect to a vertically oriented axis, and adjusting the alignment ofthe unrolling material with respect to the vertically oriented axis; acutting station for cutting the width aligned material into sectionshaving an inner surface and an outer surface, and positioning a firstsection on top of a second section, wherein the first section innersurface faces the second section outer surface; a sealing station forforming a side seam defining adjacent pouches in the aligned sections,and the width of the side seam for each pouch is 4-6 mm±1 mm; and acutting station for separating the panel of material into individualpouches along an outermost edge of the side seam, wherein each pouchincludes a front panel, a back panel, and each panel has an upper edge,a lower edge.
 9. The apparatus of claim 8 further comprising anunloading station for removing the pouch from the transport means andplacing the pouch in a receptacle.
 10. The apparatus of claim 8 furthercomprising forming a lower edge seal at the sealing station.
 11. Theapparatus of claim 8 further comprising an opening means insertionstation for adding an opening means to the pouch used to access theproduct in the pouch.